I've just spent the last two hours reading this thread start to finish. I cannot wait to see the results and the casting process. This is just an absolutely stunning piece of work, with an incredibly complete build log and great photos.
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That was from an exhibit a couple years ago in Frankfurt.
Giger Work Catalog - Exhibition at the German Film Museum, 2009
Lots of good photos to be found of this exhibit.
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I love the A3 head design and rod puppet. Putting Tom in the suit was maybe not the best approach, as you say, and kind of jarred with the leanness of the puppet. Detail wise, the double-thumbed Giger hands and the skull face half hidden by that dome kick all kinds of arse IMO, so it's the original for me, then the A3, then the Aliens, then the Space Velociraptors. I am so stealing that.
But emotive...what would you have said if they'd used Giger's 'female lips' design on the A3, then? :lol